Annexure-I Specification of Rail Grinding Machine · 2019-12-03 · Page 1 of 48 Annexure-I Specification of Rail Grinding Machine 1. General 1.1. These specifications provide the

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Annexure-I Specification of Rail Grinding Machine

1. General

1.1. These specifications provide the technical requirements for the manufacture, supply, testing,

commissioning, maintenance and operation of a self-propelled rail-grinding machine of

minimum 72 stones module (here after referred as machines) for use on the tracks of Indian

Railways. The Rail Grinding Machine to be supplied is meant for grinding the rails in

corrective mode and preventive mode, to improve the worn profile of rail head, rail wheel

contact band, its location, to remove fatigued material having micro cracks and other surface

defects on the rail head and remove corrugations. The Rail Grinding Machine shall be able to

effectively grind track on Indian Railways. The consist of RGM shall include two rest vans

and one water wagon. The supplier shall furnish, deliver, warrant, maintain and operate the

Rail-Grinding Machines as per these specifications and tender conditions.

1.2. The Technical Specifications have been drafted to cover the performance and quality

requirement of the equipment. Tenderers are requested to carefully study the specifications

and assure that their equipment fully comply with these specifications. Thereafter, if a

tenderer feels that his equipment can substantially meet the performance and quality

requirement of the specification in general but does not fully satisfy a particular

specification, he should immediately seek clarification from the purchaser prior to

submission of bids as to whether such deviation is substantive or not. Whenever there are

any such deviation(s), tenderer should mention the same in the statement of deviation from

the specification to be submitted along with bid and should clarify how his equipment will

meet the functional requirement of such clause.

1.3. The tenderer shall specify the model offered and furnish a detailed Technical Description of

the same. System/sub-systems of the working mechanisms of the Rail Grinding Machine as

per para’3 of this specification &Annexure and all the items of the specifications in general

shall be described in detail in the “Technical Description”, along with the sketches to show

the manner in which the requirement of the specifications are accomplished by the machines

(models) offered.

1.4. Photographs and video (in compact disc//Pen drive) of the type of machine offered in

working mode (showing the working of machine in real time under field conditions) be

enclosed with the offer. This shall also show close-ups of various working

assemblies/systems and the full machine. Tenderer shall also submit the names of countries

& Railways where the offered machines are working and their working can be seen if felt

necessary by the purchaser.

2. Dimensional and Operating requirements:

2.1. The diesel-powered self-propelled Rail-Grinding Machine shall be robust, reliable and

suitable for working on Indian Railways. The design and dimensions of the machine

components shall be to SI (International) System of Units standards and also comply with

provision of Indian Railways BG schedule of Dimensions-2004 incorporating all correction

slips issued .Quality assurance during manufacturing of the machine shall be according to

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ISO-9001.The welding standard followed for manufacturing of machine should be to

ISO:3834, EN:15085 or any other equivalent standard. The manufacturer should specify the

standard followed and certify that it meets the welding standard mentioned above.

2.2. The Rail Grinding Machine shall be Diesel powered (preferably indigenous) self-propelled

bogie type vehicle(s) with minimum 4 axles (2 bogies) for each vehicle. It should be reliable

and suitable for working on Indian Railway’s straight, transitions and curved track up to 10º

curves on broad gauge (1676 mm). Shared 2 axle bogies between two grinding cars and/or

between two grinding buggies/carriages are not acceptable.

2.3. The profile of the on-track machines longitudinally and in cross section during transfer as

self-propelled vehicle or towed in train formation shall be within the Indian Railways

standard metric BG schedule of Dimensions-2004 incorporating all correction slips up to

date. The minimum and maximum moving dimensions are enclosed in Annexure-III. The

tenderer shall provide sketches of the machines in plan and cross-section and shall give

calculations to show the extent of lateral shift at the ends, centre and any other relevant cross

section and to prove that the machines do not cause infringement while moving on a 10°

curve at any cross section.

2.4. Where an infringement to Indian Railways Standard BG Schedule of Dimensions (metric)-

2004 incorporating all correction slips up to date is considered necessary by the

manufacturer as intrinsic to the design of the machine for meeting the work performance

requirements laid down in this specification while meeting the safety and operational

requirements of IR, the same shall be done with the prior approval of the Purchaser and

decision of the Purchaser in permitting any such infringement shall be final and binding on

the manufacturer. Tenderers may note that acceptance of any such deviation during

consideration of preliminary design details in the offer is only in principle acceptance and

the final decision will be taken by the Purchaser at the stage of consideration of machine

design for issuing speed certificate. In the past, IR have condoned certain infringements to

such dimensions as Rigid wheel Base, Length of stocks, Distance apart of bogie centres and

maximum height of floor above Rail level in certain track machines after due consideration

of their design features vis-à-vis safety and operational requirements of IR. However,

condonation of an infringement in another track machine in the past does not by itself entitle

the manufacturer to assume acceptance of the same in other track machines by IR.

2.5. Adequate clearance shall be allowed so that no component infringes the Minimum clearance

of 102 mm from rail level while travelling.

2.6. Wherever applicable, axle load shall be less than 20.32 T with minimum axle spacing of

1.83m. Load per meter shall not exceed 7.67 tones. Axle loads up to 22.82t and lower axle

spacing may be permitted, provided the load combinations do not cause excessive stresses in

the track and bridges of IR. Further at the stage of consideration on machine design for

issuing speed certificate, stresses in the track and bridges shall be calculated by IR/RDSO

based on design data submitted by the firm as per Annexure–VIII A,B&C and decision of

IR/RDSO shall be final in this regards.

2.7. The Machines shall have a desirable wheel diameter of 914mm or more (new wheel profile).

However, lesser diameter up to 760 mm for Rail Grinding machine can be permitted

provided it meets the condition laid down in clause 2.5 at its condemnation limit as per

design and provided the rail wheel contact stresses for 72 UTS rails are within permissible

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limits. The new wheel shall have a minimum wear margin of 50mm before reaching

condemnation limit. Forged wheels to Indian Railways profile shall be provided on the

machine. The worn out wheel diameter (condemning worn out diameter) based on the

criteria of rail wheel contact stresses for various maximum axle loads are as under:

Maximum

Axle load

(tone)

Minimum

wheel

diameter (mm)

22.82 908

22.00 878

21.50 860

21.00 841

20.32 816

20.0 805

19.5 787

19.0 768

18.5 750

18.0 732

17.5 713

17.42 710

17.0 700

Permitted worn out wheel diameter should be specified by the manufacturer. The diameter of

wheel for assessment of permitted axle load will be the worn out wheel diameter. The new

wheel profile shall be as per Indian Railway standard wheel profile provided in Annexure-V.

2.8. Wheels shall be conforming to Indian Railway Standard R-19/93 or European Standard

EN13262 or any other equivalent standard (for product requirement) and design shall duly

conform to European Standard EN 13979 or other equivalent standard. The supplier shall

submit detailed design calculation along with material parameters at the time of supply of the

machine.

2.9. The non-powered axles shall be conforming to Indian Railway Standard R-16/95 or

European Standard EN 13261(EA1N) or any other equivalent standard. The supplier shall


machine.

2.10. The powered axles shall be conforming to Indian Railway Standard R-43/92 or European

Standard EN 13261(EA4T) or any other equivalent standard (for product requirement). The

design shall conform to EN: 13104 or any other equivalent standard. The supplier shall


machine.

2.11. The machines shall be capable of negotiating curves up to 10° curvature (175 m radius),

super elevation up to 185 mm and gradients up to 3% in travel mode. The supplier shall

specify the minimum attainable speed under the above limiting conditions, which in any

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case shall not be less than 25 kmph. Water wagon and camping coaches shall be considered

as part of consist/formation while travelling up to 3 % gradient.

2.12. The machines shall be capable of continuous operation during the varying atmospheric and

climatic conditions occurring throughout the year in India. The range of climatic conditions

is as follows:

Ambient temperature : -5° to 55°C

Altitude : Sea level to1800 m

Humidity : 20% to 100%

Maximum rail temperature : 70°C

All the system components on the machine shall be covered by roof or other suitable sturdy

covering so that the system & components vulnerable to moisture ingress are not adversely

affected during rains and the machine is able to work continuously even during rains

2.13. The Rail Grinding Machine in consist/formation (in composition with all its integral part)

shall be capable of travelling at a speed of 80 km/h in either direction when travelling on its

own power. In train formation, it should be capable of being hauled at a speed of 100 km/h.

It shall be possible to haul the machines in both directions at the same speed. Since the

machines are likely to cover long distances on their own power, the travel drive system

should be robust to sustain these requirements during the life of the machine without much

break down/failure.

2.14. The machines shall be capable of working without requiring power block in electrified

sections. 25KV or 2x25 KV AC power supply is used for traction through an overhead wire

at 5.5 m above rail level. On bridges and tunnels, the height is restricted to 4.8 m. The

accuracy of measurement by measuring equipments/systems of the machine shall not be

affected in any manner due to overhead electricity and also due to track circuit voltage (12 V

& 1 AMP).

2.15. The machines and any of its parts shall not infringe the adjoining track as per ‘BG Schedule

of dimensions of Indian Railways (metric)-2004 print with latest corrigendum and up to date

correction slips issued while opening and closing of work. The machine shall be equipped

with pneumatically operated brake blocks acting on all wheels.

2.16. In the work mode, no part of the machines should rise beyond 4.265 m. above rail level for

safe working in the electrified sections.

2.17. While working on double line sections, the machines shall not infringe the adjoining track

and it shall be possible to permit trains at full speed on that track. Minimum spacing of track

is 4.265m.

3. WORKING MECHANISM OF RAIL GRINDING MACHINE

3.1. The working mechanism of the rail grinding machine shall be equipped with:

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3.1.1. Rail grinding mechanism

3.1.2. Control system for rail grinding mechanism

3.1.3. Optical rail profile measurement system and its transfer to onboard computer

3.2. The rail grinding machine should be capable of producing good longitudinal profile of the

railhead continuously.

3.3. The rail grinding machine should be capable of grinding operations on plain track and

curves, track in tunnels, track on bridges having guard rails without removing the guard

rails, and track on platform lines. It should also be capable of grinding operations on track

on level crossings having check rails and curves with check rails with or without removing

check rails. Maximum grind speed should not be less than 18 kmph on plain track.

3.4. The rail grinding machine shall also be capable of grinding, if required, only one of the

rails of the track as in the case of curves.

3.5. The rail grinding machine shall be capable of grinding profile of UIC 60 Kg rail section, 52

Kg rail heads in 72/90/110 UTS strength and Head Hardened rails inclusive of fish plated

joint, insulated joints and welded joints in long welded rails and short welded rails laid on

pre stressed concrete sleepers, steel sleepers, composite sleepers and wooden sleepers. It

shall also function effectively on rails having surface defects such as wheel burns, shelling

etc. The number of grinding stones and grinding units of the machine shall be such as to

carry out controlled grinding of all rail corrugation defects and also defects of long wave

length to produce a smooth cross sectional profile without creating any sharp edge between

the rail table and gauge face.

3.6. The supplier shall ensure that the offered rail grinding machines shall be capable of

modular up gradation at a later stage and shall have such computer hardware and software

which shall facilitate easy up gradation.

3.7. The rail grinding mechanism should be electric driven, drawing power from an on-board

diesel generating set.

3.8. All the components of the rail grinding machine must be robust and capable of continuous

operation upto 8 hrs in one spell under the field working conditions. They must be

shielded against heavy heat accumulation in the work area and metallic dust generated at

the work site.

3.9. To achieve the target profile with smooth curvatures, with minimum points of singularities,

the Rail grinding machine shall have a minimum of 72 grinding stones (36 per rail), which

can be configured in various configurations to achieve different target profiles.

3.10. Each grinding module shall be controlled by a hydraulic/pneumatic cylinder for its

up/down movement.

3.11. The rail grinding machine shall be equipped with an inbuilt mechanism to stop the grinding

and lift the grinding stones/carriages when the operating speed falls below a certain

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minimum speed to avoid metallurgical damage due to heat accumulation. The minimum

speed, at which the grinding shall stop automatically, shall be as per supplier's design but it

shall be mentioned in the offer.

3.12. Each grinding module shall comprise of a ring shaped stone and a grinding motor with

suitable positioning mechanism to control the stone position, to achieve the target profile

by the various grinding module configurations. Firm shall submit their module

arrangement, Configuration should have a fully adjustable angle range of +70 degrees to

gauge and -20 degrees to field, independently controlled from the operator station in the

cab Each grinding motor spindle angle shall be accurate within ±0.25° (plus/minus one

quarter of a degree) of the designed spindle axis positioning angle. Each module shall

contain one or more grinding motors with, independent tilt cylinder for each module and

must have the capability of being positioned by the control system independent of any

other grinding module. In each module grind motor/tilt cylinder should be separated by

certain angle so that heating or other impact does not take place on rail. The tilting

cylinders should not be shared with adjacent modules and must be independent for each

module.

3.13. At the work location, the prevailing temperature may be higher than the specified

maximum temperature of 55oC. The peak load on the grinding motors, under the most

demanding conditions shall not be more than 80% of the continuous load rating of the

motor, at the prevailing temperature conditions. The supplier shall furnish the peak load

for the motors at various locations and the continuous load ratings of the motors under the

operating conditions, as per the manufacturer’s catalogues.

3.14. The grinding motor power shall be as per the supplier’s design to achieve the output

parameters laid down below and may vary with the total number of grinding motors

provided on the rail grinding machine (not less than 72). However, the total grinding

power provided on the rail grinding machine (number of motors x continuous load rating of

each motor) shall not be less than 2000HP.

3.15. The rail grinding machine shall be capable of removing, a minimum of 20 sq. mm material

from each rail(40 sq. mm for both the rails) per pass, from the rail top of a 60 kg. UIC (90

UTS) rail section, with top surface work hardened to BHN 315 to 380, while operating at a

speed of 15 kmph. While assessing the rail grinding machines performance, the test rail

profile (after grinding) shall be close to the target profile and the metal removal shall be

fairly uniform over the entire rail surface to be ground.

3.16. The capacity of rail grinding machine regarding depth of grinding per pass, for 60 kg 90

UTS work hardened rail top while grinding uniformly over full width and gauge faces at

various working speeds, shall not be less than as mentioned below :

18 kmph : 0. 13mm

15 kmph : 0. 20 mm

3.17. While achieving the above progress rate, the overall combination of grinding stones

pressure, RPM and travel speed should be such that no chattering or uneven removal of the

material occurs at high speeds nor are there any metallurgical changes or bluing of the rail

top at the minimum operating speed.

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3.18. The rail grinding machine must be capable of bi-directional grinding i.e in both the

directions on the same track without loss of metal removal capacity or productivity, while

grinding both rails simultaneously or either rail independently.

3.19. To ensure Gauge Face correction without flattening the root curve, , all of the grinding

modules shall have the ability of attaining spindle axis orientation with respect to the rail

axis, up to 70° on the gauge corner and 20° on the field corner. At all angles the grinding

effort must potentially be 100%.

3.20. While the rail grinding machine is operating at full grinding load at the maximum working

speed, the minimum life of each stone shall not be less than 5 hrs grinding time.

3.21. Each module shall be provided with a stone stop mechanism to prevent accidental contact

between the rail and grinding motor shaft chuck when the stone has completely worn out,

to prevent damage to rail or the shaft.

3.22. Rail grinding machine driving controls must be at both extreme ends of the rail grinding

machine, irrespective of driving direction. However grinding controls can be housed in one

cabin.

3.23. The unit must be capable of travelling and grinding under the following track conditions:

(i) Maximum grade 3%

(ii) Maximum curve 10°

3.24. The unit must be capable of grinding a variety of profiling and re-contouring patterns

depending on varying rail wear conditions. Such pattern changes and adjustments should

be made instantly from an on board central control panel.

3.25. The unit must have the following controls/display the following operating data at the

operator’s console:

(a) Start/stop buttons for individual motor and master stop button (to stop all grinding

motors).

(b) Current meters for various grinding modules and motor grinding power control.

(c) Grinding Module/Grinding carriage up/down control.

(d) Operating speed monitor and control.

(e) Stone condition monitor.

(f) Deviations in motor spindle angles.

(g) Any other data monitor/control required for proper operation and control of the

working, depending on the supplier’s design.

(h) Angle setting of different grinding module.

3.26. a. There shall be computer controlled monitoring of input and output of different

electrical/electronic devices with the facility of display of input/output so as to monitor

the functioning of electrical/electronic devices.

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3.26.b. The computer controlled functions may be as per the supplier’s design, but as a

representative illustration, the following functions shall be computer controlled

(a) Auto horsepower adjustment of grinding stones with change in pattern

(b) Carriage Raising and lowering.

(c) Module raising and lowering.

(d) Pattern data input from Rail Profile measurement units.

(e) Storage of Profiles.

(f) Grinding pattern selection and down loading to grinding controls

3.26.c. The computer controlled system shall have the facility of System diagnostics in

operator’s cabin (at least in one cab) which should be able to do following:

(a) Detection of short circuit, open circuit conditions and measurement of amperage

in connection to control devices.

(b) Diagnostics modules shall be provided for troubleshooting of various electronic

printer circuit boards used up to card/board level fault finding.

(c) Communication between various sub systems used in the system shall be

provided as a diagnostics feature.

3.27. The on board computer will monitor the main system of rail grinding machine and

maintain a log of following items:

(a) Grinding Motor performance (amps).

(b) Stone usage.

(c) Grinding Motor idle amp.

(d) Stone spark time.

(e) Motor life.

(f) Performance monitoring

- Quantitative assessment of metal removal from each km of track to achieve

target profile.

- Percentage deviation of ground profile from target profile

- Grinding speed and no of grinding passes

- Quantum of work done in pass km

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- History of existing rail profile, target profile and grinding pattern followed for a

given km of track.

3.28. The rail grinding machine must be capable of automatic adjustment of grinding patterns

from the operator’s cab. The supplier shall furnish details of all possible number and

patterns subjected to minimum of 50 patterns. The on-board computer must be capable of

storing all these grinding patterns and changing from any of these patterns to any other

within the length of the grinding consist.

3.29. It shall also be possible to record the grinding length vis-à-vis time on a print out to obtain

information on the rail grinding machine output. The system shall be able to produce

performance parameters and progress of work such as grind length, speed of grinding,

number of passes done, pattern used, pre/post Grind Quality Index (GQI) etc in a way that

should facilitate its transfer to pen drive at the end of day’s work.

3.30. The grinding method must ensure the complete re-profiling of the railhead by metal

removal.

3.31. All the grinding stones shall be equipped with an automatic vertical control and locking

device preserving the stone from dropping into pitch corrugation.

3.32. All the grinding units shall be so designed that it can be lowered or raised from grind cabin.

Lowering and raising of grinding units should be automatic, electronically operated, which

can be applied either on one rail or on both rails simultaneously.

3.33. The rail grinding machine shall be equipped with Rail Grinding templates for Board Gauge

(1676 mm), with minimum four different profiles (a) Tangent track (b) The high rail in

mild curves (c) The high rail in sharp curves (d) Low rail in both mild and sharp curves,

because worn rail profiles are not always centrally located with respect to the vertical axis

of the rails.

3.34. To ensure minimum vibration of the rotating grinding stones, a self-centering system for

holding the stones shall be provided.

3.35. The grinding trolley shall be designed for raising and lowering operation from grinding

control cabin.

3.36. The grinding power per grinding stone shall be minimum 25 Horse Power.

3.37. The rail grinding machine must be equipped with an obstacle sensing/detection system

with manual lifting of the grinding carriages through controls from operators’ cabin before

approaching the obstacle and restarting of the grinding process after the clearance of the

obstacles. The supplier shall specify the distance left unground after the clearance of the

obstacles at various operating speeds. This distance shall not be more than 12 m for an

operating speed of 15 kmph.

3.38. The rail grinding machine must be capable of setting down or picking up grinding stones in

curves also.

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3.39. Grinding carriages should be capable of being raised and lowered and locked into position

on curved track up to 10 degrees.

3.40. The grinding stone must be centered over the grinding spot at all intended grinding angles.

To ensure proper positioning and angle of the grinding stone, the support structure must be

equipped with pivot to permit the angular adjustment of the motor/stone in relation to the

rail for centering of the stone over the area with adequate force to produce desired grinding

power.

3.41. The grinding motors shall be controlled through suitable starter control for

starting/stopping of motor.

3.42. Grinding patterns must be balanced and not change with curve super elevation of the track

on which the rail grinding machine is operating except for changes will made from system.

The rail grinding machine must be equipped with a system to maintain a positive pressure

and constant reference to the gauge face of the rail.

3.43. The rail grinding machine must be equipped with a vertical rate of correction feature to

restrict the grinding in corrugation valleys, while smoothening the crests. For maximum

grinding effort on rail running surface variations, the unit must be equipped with selective

vertical stability control. The tenderer shall furnish the details of the mechanism to achieve

this.

3.44. The unit must be capable of grinding any worn rail profile to shapes within plus or minus

0.30 mm of the selected target profile.

3.45. Metal removal rates must not vary more than 25% between grinding of rail with hardness

ranging from 280-380 BHN.

3.46. The surface finishes after the grinding shall be that corresponding to RMS value of 12

microns roughness or less.

3.47. The rail grinding machine must be supplied with adequate lighting to perform grinding at

night safely and efficiently.

3.48. The rail grinding machine shall be equipped with suitable spark arresters to prevent sparks

from flying around and be a potential fire hazard. The spark arresters shall be suitably

designed to withstand the heat generated at the work spot and the flying metal sparks.

3.49. The rail grinding machine should have adequate water capacity to prevent and fight fires,

and to carry on grinding irrespective of terrain or dry weather conditions. A minimum

20000 liters water storage capacity should be available on the rail grinding machine. There

shall be separate arrangement of 55000 liters storage of water container in the rail grinding

machine consist by way of a separate wagon for use during prevention of fire. It should be

possible to connect the water storage on the attached wagon with the rail grinding machine

storage and use it for arresting fire as and when required. The visibility requirement of the

rail grinding machine as specified in clause 13.1 shall not be obstructed on this account

3.50. The rail grinding machine shall be equipped with two water cannons (one in front and

another in rear with) of capacity up to 600 liters each per minute throughout with a reach of

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40 meters. The rail grinding machine shall also be equipped with separately controlled

sleeper and ditch spray, for front and rear.

3.51. There should be an installed, integrated backup of the following critical sub-systems to

ensure maximum availability and minimal chances of disruption of rail grinding machine

operations:

a. Water system/pumps

b. Hydraulic pumps/motors

c. Air compressors

A suitable by-pass mechanism should be installed and integrated to main system to operate

the rail grinding machine with backup assembly.

3.52. The rail grinding machine shall be provided with a set of optical rail profile measuring

system integrated with the onboard computer both in front of the rail grinding mechanism

as well as rear of the rail grinding mechanism.

a. The profile measurement system should be able to capture rail profile both ahead of and

behind the grinding machine and should have capacity to store data of rail profile at

least 200 km of track length for real time comparison of rail profile before grinding and

after grinding. Optical rail profile measurement system should have facility to transfer

data to onboard computer without human interface.

b. The on board profile measurement system, in a real time basis, should show the actual

rail profile ahead of work and after the work and difference between the measured

profile and selected target profile. The system should save the captured rail profile data

along with input location data such as milepost, curve-data, grinding, speed patterns

used etc.

c. Electronic/computerized rail profile data processing system and software plug-ins to

grind the existing rail profile to a selected target rail profile shall be provided on board

to Rail Grinding Machine. Rail Grinding Machine should be equipped with required

following hardware and software-

i. To capture, store and process rail profile data from other measuring devices of rail

profile,

ii. Optional merit given to supplier having quantitative assessment of metal removal

per meter of rail to achieve target rail profile,

iii. Recommended grinding pattern to achieve a target rail profile

iv. Comparative picture of target profile and profile achieved after grinding on real

time basis,

v. Quantitative assessment of deviation of ground profile from target profile.

d. The rail grinding machine should be provided with the necessary software and hardware

system to store a library of desired railhead profiles (templates) and to calculate on real

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time basis the amount of rail grinding to be done. The supplier shall be responsible to

provide technical support and services for software maintenance and up gradation

during warranty and subsequent working life of the rail grinding machine (minimum 15

years).

e. It should give:

(i) Best/optimum pattern to use for grinding.

(ii) Number of grinding passes needed in order to achieve a predefined acceptance

envelope.

(iii) Grinding speed for suggested pattern and profile

f. To develop library of target profiles for various rail sections on different route, supplier

of rail grinding machine will design the target rail profiles for all the locations where it

will be deployed to work. The system should be equipped to store data of rail profile

before grinding, its target profile and rail profile after grinding in an integrated way so

that it could be retrieved for any given location of track.

3.53. The machine should be equipped with GPS, GSM/GPRS based remote monitoring

capabilities for various track parameters and vital parameters of track machine, It should

also have facility to interface with Human Machine Interface (HMI) / Display and various

other sensors. The data transfer unit should be compatible with the Track Management

System (TMS) of IR.

4. DIESEL ENGINE/ELECTRIC GENERATOR:

4.1. The machines shall be powered by diesel engine(s) preferably indigenous, with proven

record of service in tropical countries with wide service network in India. Robust

construction and low maintenance cost are of particular importance. The manufacturer of

the engine shall have acquired quality assurance certification of ISO: 9001. Adequate

allowance shall be made to provide adequate reserve power to take care of the working of

machines under most adverse climatic conditions, heavy grinding requirements on steep

gradients, and to provide back up power in case of failure of one of the engines.

4.2. The supplier shall furnish the details of diesel engine and its controls to assess its

conformity with the engines already operating on track machines on Indian Railways. The

engine should be of such design /brand which are being manufactured indigenously and/or

such designs having after sale service facilities available in India. The supplier should

furnish the information regarding agency which will provide after sales service support and

availability of spares in India.

4.3. Diesel tank fuel capacity of the rail grinding machine should not be less than 21,000 lts. or

40 hrs of working. Tenderer should mention the fuel storage capacity and average fuel

consumption of machines.

4.4. The engine shall be mounted on suitable Anti-Vibration Mountings.

4.5. High speed diesel oil to Indian Standard Specification shall be normally used.

4.6. Sight glass type fuel measuring gauge preferably of full height shall be provided on the fuel

tank.

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4.7. For starting the engines, storage batteries of well-known make shall be provided. The

engine shall be push button start type or key type.

4.8. Since the engines are to work outdoor under extreme dusty condition, the air intake system

shall be designed suitably so as not to allow dust through air intake system.

4.9. There is likelihood of dust deposition over the engine body and surrounding area over the

lubricants spill-over. These should be easy to access for daily cleaning and routine

maintenance. In case, air cooled engines are proposed by the supplier, maintenance

equipment for cleaning and maintenance of the air cooling fins shall be provided by the

supplier along with the machine.

4.10. The engine parameter monitoring gauges like temperature, rpm, lube oil pressure shall be

direct reading type mounted on the engine backed up by electrical/mechanical gauges in the

operator’s cabin showing the absolute readings along with safe limits suitably coloured.

There shall be audio visual warning (safety mechanism) to the operators in case of any of

these parameters exceeding the safe limit, and engine should shut down automatically.

4.11. Suitable and rugged mechanism should be provided to start the prime mover at minimum /

no load and gradual loading after the start of the prime move.

4.12. The diesel engines of Rail Grinding Machine shall be coupled to the electric generator(s) of

a continuous rating to suit machine-operating requirements. Suitable cooling arrangement

for the generator shall be provided. The electric generation parameter monitoring gauges

shall be provided like wattmeter, voltmeter, ammeter, frequency meter etc. Generator shall

have over voltage protection.

4.13. The grinding power should be on a common bus to ensure grinding with all grinding

modules may continue in case of failure of one of the engines / generators. The supplier

shall furnish the details of power requirement for working under normal conditions as

specified in clause 3.15 and total power provided on the machine.

4.14. In order to adhere to pollution control norms, the diesel engine should be electronically

controlled emmissionized engine with minimum compliance to tier 2 stage.

4.15. The engine should have Electronic Control Module (ECM) or similar arrangement for

taking out operating parameters on real time basis such as RPM, load, temperature,

pressure and diagnostic data as well as trip and historical data. These data should be

displayed and stored on a centralized computer and monitoring system. It should also be

possible to transfer these data on USB device through the centralised computer based

control.

4.16. The engine should be enclosed in a weather protective, sound and dust resistant enclosure

to minimise engine noise and to prevent oozing out of oil spills etc. from engine area to the

adjacent machine components, hoses, electrical cables fittings as a protection against fire.

All doors on the enclosure shall be strategically located in areas as to allow ease of

maintenance of the engine and allow good access to and visibility of instruments, controls,

engine gauges, etc. Sufficient louvers shall be provided to allow the total engine cooling air

requirements used in this application.

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5. DRIVE MECHANISM

5.1. The machine should be provided with an efficient traction drive system for traction during

the operation. The machine’s driving system shall be through hydro

dynamically/hydrostatic capable of achieving full speeds in travel mode in both the

directions. The system should be so designed that all the driving wheels work in

synchronization and there is no slippage / skidding of the wheels during the work drive.

5.2. The driving mechanism, in working mode, shall be adequately designed to handle the

acceleration and braking forces.

5.3. Suitable differential systems may be provided between coupled wheels on the same bogie.

5.4. Suitable flow divider/throttling arrangement may be provided to equalize the tractive effort

amongst different bogies.

5.5. The supplier shall provide the necessary technical details including circuit diagrams and

detailed technical specifications of all electrical/electronic parts to confirm the above

requirements.

5.6. Adequate gauges to monitor driving and working performance of machine should be

provided in working and driving cabins near operator’s seat. Solenoid valves shall be

provided near linkage assembly, for indication, flow control and carrying out necessary

adjustment in the field. To the extent possible hydraulic and pneumatic

component/assembly should be fixed at suitable location preferably on the side frame of

the machine so as to avoid the need of going on top of the machine for day-today

maintenance schedules.

5.7. The pneumatic circuit should be provided with air dryer for the smooth working of

pneumatic components.

5.8. The machine shall be equipped with adequate safety circuit such that if any unit/part which

may endanger the safety is unlocked and the air pressure in brake circuit is less than 5 bars,

the machine shall not move during run drive. The indication of locking and unlocking of all

units should be displayed in the cabin.

5.9. Onboard system for online filtration and monitoring the quality of hydraulic oil in

hydraulic circuit should be provided. The gauge should clearly indicate if the hydraulic oil

is contaminated beyond the permissible limits and requires immediate replacement.

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6. COOLING SYSTEM:

6.1. The cooling system shall be efficient and designed for a maximum ambient temperature of

55°C. Supplier must note that the machine shall be working under extreme dusty conditions

and the cooling mechanism should be maintainable under these conditions.

6.2. Adequate heat transfer arrangement shall be designed and provided so that the system oil

temperature does not go beyond specified range.

7. REST VANS:

7.1. One No’s crew rest van having total resting capacity of about 12 to 15 persons will be

integral part of the Rail Grinding Machine and shall be supplied with the same and for

second rest van with driving control as a last vehicle of the RGM.

7.2. Typical layouts of coaches, with/without operational controls are given at Annexure I & II

of the Technical Specification. These layouts are for guidance of tenderers in respect of the

facilities required and general arrangement thereof.

7.3. Tenderer can propose modifications in layout as a part of technical proposal while

providing the required facilities as per typical layout. Overall dimensions of the rest van

will be within (+/-) 10% of the typical layout subjected to conformity to the Indian

Railways standard metric BG schedule of Dimensions-2004 incorporating all correction

slips up to date. The modifications proposed by tenderer will be discussed with tenderer

during technical evaluation and necessary modifications required by IR will be

incorporated by the tenderer as per mutual consent. If any further modifications are

required by the successful contractor at the stage of detailed design, the same will be

subjects to approval of RDSO.

7.4. Rest vans should be air conditioned and fully furnished for comfortable stay of operation &

maintenance crew and IR personnel.

7.5. Minimum amenities to be provided in rest vans, its color scheme and other details shall be

as per Correction Slip no.12 of IRTMM-2000.A Washing machine, Microwave oven and

communication gadgets are also to be provided.

8. BRAKES:

8.1. Machine shall be equipped with compressed air brake system applying brakes equally on

all wheels and provision shall be made to connect air brake system of the machine to that

of camping coach/wagons when the machine is hauling it. Fail safe braking mechanism

system shall be provided so that in case of any failure of brake circuit, will result in

automatic application of brake. The pneumatic parking brake should also be spring loaded

so that in case of drop in pneumatic pressure below certain value the brake will be

automatically be applied. The brakes shall be protected from ingress of water, grease, oil or

other substances, which may have an adverse effect on them. The brake lining shall be

suitable for high ambient temperature of 550

C.The force required for operating the brake

Page 16 of 48

shall not exceed 10 kg at the handle while applying by hand and 20 kg on the pedal, when

applied by foot. In addition, mechanical brakes shall also be provided for parking.

8.2. The rail grinding machine shall have provision for suitable air brake system in the driving

cabins to brake the entire consist including camping coach/crew rest van and water wagon

attached as a part of its consist/formation. Fail safe braking mechanism system shall be

provided so that in case of any failure of brake circuit will result in automatic application of

brake. The pneumatic parking brake should also be spring loaded so that in case of drop in

pneumatic pressure below certain value the brake will be automatically be applied.

8.3. The machines shall be equipped with suitable air brake valves so that while working in

train formation, machines can be braked by the traction vehicle.

8.4. There should be provision of emergency brake application in the machine either travelling

alone or coupled with the coach/wagons, in addition to the normal braking system of the

machine, using the compressed air. The emergency braking distance (EBD) of the machine

on the Indian Railway Track, at the maximum design speed on level track shall not be more

than 600 m. Design calculations for the braking effort and EBD at the maximum design

speed of the machine on level track & at falling grade of 1 in 33 should be provided by the

supplier.

8.5. Provision of “Manual operated hand brake” system shall be provided.

8.6. Clearly visible brake lights shall be provided at both the ends of the machine, which will be

automatically operated when brake is applied and switched off when brake is released. This

will be to alert the operator of machine following this machine when the machines are

working in groups.

9. HORN, HOOTER AND SAFETY MECHANISM:

9.1. The Machines shall be provided with dual tone (low tone & high tone) electric horns/ at

suitable locations facing outwards at each end of the machine for use during travelling to

warn the workmen of any impending danger. Controls/switches shall be provided in close

proximity to the driver permitting the driver to operate either horn individually or both

horns simultaneously. The horns shall be distinctly audible from a distance of at least 400

m from the machine and shall produce sound of 120-125 dB at a distance of 5 meter from

horn (source of sound). The higher tone horn shall have fundamental frequency of 370 ±15

hertz. These electric horns shall be operated by means of push buttons provided in the cabs.

9.2. The Machines shall have arrangement for flasher lights at both ends.

9.3. Pneumatically/electrically operated hooters capable of producing intensity of sound

between 105-110 dB at a distance of 5 meter (when measured in still air in a closed room)

and variation in intensity of sound shall not be more than 5 dB. The hooter shall be

provided facing outwards at each end of the machine at suitable locations, operated by

means of push buttons provided in the cabins to warn the staff working on/around the

machine about approaching train on adjoining track. Additionally switches for such hooter

shall be provided outside on the machine frame and near the both side exit gates so that it

can be operated by staff present at work site near the machine. The hooter shall also be

operatable from remote point at a distance of at least 300 m from the hooter.

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9.4. Safety equipments like jacks, pullers, tirfor and other such equipments specific to the

machines for restoring failed units of the machines during working, shall be provided on

the machines. The tenderer should submit the list of safety equipment to be provided.

9.5. Adequate numbers of safety stop/ switches should be provided all around so that in case of

any danger to worker as well as hitting of any obstructions by working unit like signalling

cable, joggle fish plate etc. during work,so that the operator can be warned or the machine

can be stopped immediately.

9.6. In addition, separate electric horns with push bottom type switches shall be provided at

suitable locations in all cabin(s) and on machine body for communication between the

machine staff about infringement/malfunctioning or any other trouble

9.7. Machines shall be provided with emergency backup system to wind up the machines in the

event of failure of prime mover or power transmission system of the machine. The

emergency backup system should able to be operated manually and may also use a manual

hydraulic power pack in addition to the emergency generator / battery based electric

hydraulic system.

9.8. The grinding carriages of rail grinding machine should have non-flammable shields and

guards so as to avoid damage due to sparks, grinding dust and flying debris.

9.9. The rail grinding machine shall have a UV and Temperature based fire detection system

that will alert the operator. There shall be an arrangement that when the fire extinguisher is

activated,if electronic control of engine detected malfunction, the engine automatically

shuts down.

9.10. There shall be arrangement on rail grinding machine to prevent dust from the grinding

process from escaping into the air. A suitable and efficient “dust collection system” shall

be provided on the machine.

10. HOOKS AND BUFFERS:

The machines shall be fitted with transition CBC couplingas per RDSO specification no.

56-BD-07 with latest revision along with side buffers to RDSO drawing no. RDSO/SK-

98145 with latest alteration on both the ends for coupling it with other vehicles for running

it in train formation and for attachment with the coach, locomotives and wagon.

11. HEAD LIGHT, FLASHER LIGHT AND OTHER LIGHTING ARRANGEMENTS:

The electrical equipment to be provided on machines shall conform to relevant standard

specifications and shall be suitable for Indian climatic conditions. The machine shall be

equipped with Twin beam headlight assembly conforming to RDSO’s specification no.

ELRS/SPEC/PR/0024 Rev-1, Sept 2004 with latest amendments ensuring a light intensity

of 3.2 lux at ground level at track centre at a distance of 305 mts. away on a clear dark

night, at each end and with two front and rear parking lights, which can be switched to red

or white according to the direction of the travel. Powerful pressurize floodlights shall also

be provided to illuminate the working area sufficiently bright for efficient working during

night. In addition minimum eight power point locations shall be provided on outside frame

of the machine two in front, two in rear and two on both sides for providing lighting

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arrangements during night working. The umber colour LED based flasher lights producing

not less than 500 lux at 1 meter and 55 lux at 3 meter in line measurement in axial direction

from flasher light shall be provided at both ends on the machine to give indication for the

train arriving on the other line.

12. CHASSIS AND UNDERFRAME:

The chassis of machines shall be fabricated from standard welded steel section and of steel

sheets, so as to permit transportation of the machine in train formation without endangering

safety of the train. The under frame shall be constructed with rolled steel section and/or

plates and shall be designed to withstand a maximum static squeeze test load of 102t at

buffers i.e. 51t at each buffing point without any permanent distortion. The under frame

shall be sufficiently robust for safe travel of the machine in train formation.

13. CABINS:

13.1. The machines shall be equipped with fully enclosed air conditioned and pressurized cabins

with safety glass window at both the ends. It shall be possible to have a clear view of the

track ahead while driving the machine in both the directions from the cabins at either end.

The cabin layout shall be such that, before leaving the machine, the operating staff has full

view on both the sides, to avoid any danger to them from trains on the adjacent tracks.

13.2. The gauges, instruments and controls panel shall be suitably located in the operator’s cab

so that they can be observed without undue fatigue to the operator.

13.3. The operator’s cabin shall be ergonomically designed to have easy access to all controls.

13.4. Screen wipers preferably operated by compressed air or electricity shall be provided on the

windscreens

13.5. Suitable number of fire extinguisher shall be provided in all the vehicles. The chemicals

used for extinguishing fire by such fire extinguishers shall not chemically react with

electronic equipments/components, PCBs, cables etc.

13.6. The machines shall be provided with well-defined space for keeping the tools and spares

required for at least one week of operation and onsite repair of the machine to attend the

breakdowns and other working requirements.

13.7. Large window shall be provided in both cabs of the rail grinding machine at low level to

ensure good visibility for the operator controlling working and driving of machines to

observe the track features and to operate the controls based on the features/obstructions

being approached and cleared Facility of driving the machine for travelling purpose shall

be from both the cabins. All travelling and grinding control shall be housed in the air-

conditioned cabins.

13.8. Inter-communication system wired/wireless shall be provided inter-connecting all the

cabins and coaches and outside of machine should be so oriented that the operator, seating

on the seat of either cabins/working cabin, can distinctly hear the conversation and

communicate with other staff.

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13.9. The machine shall be equipped with speed indicator and recording equipment of range

between 0 - 120km/h for recording the speed of the machine in real time basis. The

recorded data should be retrievable on computer through memory card/pen drive. It should

be provided in the driving cabin at suitable place and recording system should have

sufficient memory to keep the speed record of minimum 15 days which should always be

stored for retrieving as per requirement

14. TOOLS AND INSTRUCTION MANUALS:

14.1. Each machine shall be supplied with a complete kit of tools required by the operator in

emergency and for normal working of the machines. The list of tools to be provided shall

also include all tools necessary for maintenance and repair of the entire machine including

specialized equipment, like hydraulic jacks, welding equipment, wheel truing shoes,

refractometer, power tools, air hoses/wands, etc. all special tools shall be listed and

catalogued illustrating the method of application.The list can be modified to suit the

purchaser's requirement, while examining the offer. The supplier shall include all items,

tools and accessories required for proper operation, servicing, maintenance, assembly

overhauling, periodical overhauling of the machine along with the offer and not mentioned

in these specifications and supply the same along with the machine.

14.2. Detailed operating manual, maintenance and service manual shall be specifically prepared

in English Language and four copies of these shall be supplied with each machine.

14.3. The manufacturer shall also supply circuit diagrams of electrical hydraulic, pneumatic and

electronic circuits used on the machine. Trouble shooting diagram/table shall also be

supplied. In addition, the supplier shall provide dimension drawings with material

description of items like rubber seals, washers, springs, bushes, metallic pins etc., main

features such as type, RPM & discharge etc. of items like hydraulic pump-motors, and the

tenderer shall furnish the details of such other bought out components/assemblies. These

shall be specially prepared in English language and four copies of these shall be supplied

with each machine.

14.4. Complete technical literature in english to be supplied with the machines should be sent 3

months in advance of inspection of the first machine to RDSO for their review regarding

adequacy and manner of detailing. Necessary modifications and further detailing as per

RDSO’s comments should be carried out and compliance should be reported to RDSO as

well as the Inspecting officer of the first machine.

14.5. The firm shall provide detailed technical drawings and specifications of wheels and axles

used on the machines. The above details shall be provided in four sets with each machine.

14.6. One set each of all the manuals and diagrams should be sent to the Principal/IRTMTC,

Allahabad, ED/TM/RDSO, Lucknow, DTK(MC)/ Railway Board and

Director/IRICEN/Pune along with supply of first machine. In case there is any subsequent

amendment in above documents based on field performance, the amendment/amended

documents should also be sent to above mentioned authorities.

14.7. Each machine should be supplied with following Equipments-

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a. Two contact based rail profile measuring equipment shall be supplied by

manufacturer along with machine as per RDSO Specification no. TM/SM – 323

b. Bar gauge with appropriate templates

c. Digital inclinometer

d. Rail Hardness measuring equipment

e. Rail Roughness measuring equipment

15. SPARE PARTS:

15.1. The expected life of the components shall be advised along with their condemning limits.

15.2. The manufacturer shall be responsible for the subsequent availability of spare parts and

grinding stones to ensure trouble free service for the life of the machine. (Minimum 15

years)

15.3. For indigenous parts and bought components and assemblies, the source (original

equipment manufacturer’s reference and part no.) and other relevant technical details shall

be supplied while offering the first machine for inspection.

16. MAKER’S TEST CERTIFICATE:

16.1. Copies of maker’s certificate guaranteeing the performance of the machine shall be

supplied in duplicate along with the delivery of each machine.

17. OPERATORS:

17.1 The number of operators and allied staff for working of the machines under normal

condition shall be indicated, specifying their duties and minimum qualifications.

18. OPTIONAL EQUIPMENT:

18.1 Tenderer is expected to quote for optional equipment separately for each item giving the

advantages/functions of such optional equipment. Tenderer shall also indicate whether

such equipment is already in use on machines elsewhere indicating the user Railway

system.

19. INSPECTION:

19.1. While inspecting the machine before dispatch from the supplier’s premises, the inspecting

officer to be nominated by the purchaser shall verify the conformity of the machine with

respect to individual clause of technical requirements laid down in this specification. The

machine’s conformity/non-conformity with respect to each item shall be jointly recorded,

before the issue of the “Inspection certificate and approval for dispatch of the machine” as

per Annexure-VI enclosed.

19.2. Following arrangements shall be made by the supplier/Manufacturer at the inspection

premises for carrying out inspection of the machine by inspecting officials:

i. Machine to be stabled on straight & level BG track. The length of the track should be

at least 10 m more than buffer to buffer length of machine.

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ii. In order to check Maximum Moving dimensions in cross section, a sturdy frame of IR

Max Moving Dimensions shall be provided by the manufacturer and passed over the

machine holding it perpendicular to track, centre aligned with track centre.

Adequate arrangements shall be made to the satisfaction of inspecting official.

19.3. The following documents shall be provided to the Inspecting Officer at least 30 days in

advance of the date of inspection.

i. One copy of complete technical literature mentioned in clause 14, in English language,

including operation, service and field maintenance manuals/instructions and complete

electrical, hydraulic and pneumatic circuit diagrams, trouble shooting charts,

component drawings/ description and other relevant technical details as a reference

documents for the inspecting officer.

ii. Cross section of the machine super imposed on IR maximum moving dimensions

envelope shall be provided to IO in advance.

iii. Clause by clause comments of the manufacturer to be sent to Inspecting Officer (IO) in

advance for his review. Comments should state manufacturer’s conformity of

compliance of each of the requirement stated in each clause, elaborating where

necessary the details/manner in which the requirement has been complied. The

proforma of draft inspection report for the clause-wise comments is given below:

Clause No. Clause Comments of

Supplier/manufacturer

Comments of Inspecting

Officer

(To be filled by inspecting

officer)

iv. Manufacturer’s Internal Quality Inspection Report of the machine.

v. Manufacturer’s quality certificate and/or test reports for bought out assemblies/ sub-

assemblies to be provided to IO, containing serial number wherever applicable.

vi. Draft Inspection Report to be prepared by the manufacturer, containing all annexure

mentioned at para 19.4.

vii. Details of arrangements made for checking Maximum Moving Dimensions for his

approval.

Supplier will incorporate amendments/further clarification in the above documents to the

satisfaction of the Inspecting Officer keeping in view the Inspecting Officer’s comments, if

any.

19.4. List of documents to be annexed in the draft Inspection Report should include:

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i. Maker’s Test Certificate.

ii. Manufacturer’s Internal Quality Inspection Report

iii. Quality Certificates of Bought out assemblies/ sub-assemblies

iv. Cross section of the machine super imposed on the IR MMD

v. Vogel’s diagram

vi. List of spare parts to be dispatched along with the machine

vii. List of tools to be dispatched along with the machine

viii. List of. Manuals, Drawings, Spare Parts Catalogues, etc. to be dispatched along

with the machine, duly indicating the number of sets of each.

Above documents shall be part of final inspection report

20. Issue of Provisional Speed certificate

Whenever a new rolling stock is introduced in Indian Railways, a provisional speed

certificate is issued by RDSO, based on certain design parameters of the vehicle. Final

speed clearance of the vehicle is given after conducting detailed oscillation trial of the

vehicle, which is a time taking process. Therefore, issue of provisional speed certificate for

the vehicle becomes a necessity and based on the same, the approval of running of the

vehicle on Indian Railway track is taken from Commissioner of Railway Safety. For issue

of provisional speed certificate, the following actions are required to be taken by the

suppliers.

A- Current suppliers, whose models are approved:

The supplier shall give details of the model, year of introduction in Indian Railway, details

of speed certificate issued etc. The supplier shall certify that no change has taken place in

the model being offered with respect to design of under carriage i.e. suspension system

/arrangement, wheel & axle assembly, bogie, braking arrangement loading pattern of the

vehicle etc. and the distribution of axle loads, lateral forces, unsprung mass and braking

force coming on rail is the same. If, there is any change in above respect, the action shall be

taken as detailed in para (B) below:

B- Current suppliers, whose models are not approved / or new:

As soon as the supplier completes the design of the machine as per specifications, the

technical details as per Annexure (VIII/A,B&C) shall be supplied for processing of

provisional speed certificate for the machine so that it can be permitted to move on track.

On case-to-case basis, more technical details (other than mentioned in Annexure VIII/A, B

& C) can also be asked for issue of provisional speed certificate for the machine.

C- New suppliers, whose models are new:

The technical details shall be supplied as detailed in para (B) above.

21. MARKING & COLOUR:

21.1. The machine body shall be painted in golden yellow colour, conforming to RDSO

specification No M & C/PCN/109/88 (with latest amendment) to minimum DFT of 80 mm.

Colour code to be ISC: 356.

21.2. Following should be written on the machine at appropriate location (as per Annexure IX)

(i) Indian Railway’s logo of height between 300 mm to 600 mm as suitable on all four

faces of the machine.

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(ii) On both side faces, below the Indian Railways logo, the text “ INDIAN

RAILWAYS” to be written in Bold and in Black colour of size equal to or slightly

smaller than the size of logo but of size not less than 250 mm.

(iii) Below the text “INDIAN RAILWAYS” mentioned above, Machine model and

manufacturing Year should be written in black color and in letter of size less than

the size in which Indian Railways is written but not less than 200 mm in any case.

(iv) If desired by the Manufacturers, his Name may be written in size not more than 150

mm and should not be at more than four locations. Also the Manufacturers Logo

may be provided at not more than two Locations and should be of size less than

200mm.

22. Acceptance test-The acceptance test as below shall be carried out at the time of

commissioning of machines in India at the consignee Railway.

22.1. Rail Grinding Machine : The acceptance test of Rail Grinding Machine shall consist of:

A. Dimensional test of the loading gauge, maximum moving dimensions, buffer heights,

clearances etc.

B. Testing for negotiability of 10-degree curve and 1 in 8.5 turnouts.

C. Train running speed tests (light running) on the Indian Railway main line track in

accordance with the procedure outlined at Annexure –VII.

D. Construction and engineering of the machine.

E. Output performance quality tests with High carbon 90 UTS/110 UTS H.H. rails with

60-kg/52 kg UIC section.

F. Profile of the rail section shall not be deformed.

G. For the purpose of metal removal capability of the machine (clause 3.16), 5 sites of

minimum 500m each shall be selected. At each site measurement of both left and right

rail shall be taken.

i. At each site, the machine shall grind a length of at least 500 meters to ensure that the

stones are not heated up.

ii. The profile of the rail shall be close to the desired profile.

iii. The rail hardness shall be measured and recorded.

iv. A each site, on the test rails, 5 X-sections shall be selected on both rails. These X-

sections shall be at least 2 meters away from any weld/fish plated joint and not in

heavily corrugated rail.

v. The X-sectional area shall be recorded, at each X-section, before the grinding, and

after 1 grinding pass. The working speed, while grinding shall be maintained as

specified.

vi. The average material removal per pass for the site shall be the average of material

removal per pass at 5 X-sections.

vii. The average material removal per pass at the specified speed at each of the 5 sites both

left and right rail separately shall be more than that specified in clause 3.15.

H. For the purpose of depth of metal removal capability of the machine (clause 3.16), 5

sites of minimum 500m each shall be selected for carrying out tests at the speeds

mentioned in clause 3.16. At each site, measurement of both left and right rail shall be

taken:

i. At each site, the machine shall grind a length of at least 500 meters to ensure that the

stones are not heated up.

ii. The profile of the rail shall be close to the desired profile.

iii. The rail hardness shall be measured and recorded.

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iv. 5 points shall be chosen at 5 locations across the X-section, one towards gauge face

side, three in the middle of rail top and one towards non-gauge face side such as to

cover full width of rail head, at 5 X-sections on both rails at each of the 5 sites.

v. The working speed, while grinding shall be maintained as specified. The depth of

metal removed shall be measured by measuring the depth of cut before and after 1

grinding pass (as per para no. 21.1/G/v). Measurement to be done with Contact based

Rail profile measurement Device with or better precision/accuracy.

vi. The average of the 25 observations at each site for each rail shall be worked out. The

average depth of metal removal per pass for the site shall be the average depth of

material removed for all 25 test points.

vii. None of the average depth of metal removal per pass for a site, out of 5 selected sites

for both rails should be less than as specified at clause 3.16 for the respective grinding

speed.

I. Stoppages of work not attributable to machine shall be discounted.

J. The difference in the target profile and ground profile ie profile achieved after

grinding, shall not more than + 1% in terms of cross sectional area of rail head.

K. The machine will also be operated at suitable locations in working mode for

continuous 5 hours to ensure the machine’s continuous working capability for this type

of work and test the life of the grinding stones as specified at clause 3.20.

22.2. Should any modifications be found necessary as a result of the tests, these shall be carried

out by the supplier at his own expense.

23. TRAINING:

23.1. The supplier shall impart professional training to IR Personnel in various aspects of

operation, maintenance and management of the machine, planning and designing rail

grinding program, inspection, monitoring, quality control and review as per the brief scope

defined in Annexure-IV.

The tenderer will submit detailed program covering scope and coverage in detail, place and

manner in which the training will be imparted so that a satisfactory level of knowledge and

skill is developed by IR Personnel for satisfactory implementation of grinding program

23.2. E-Learning courses module should be arranged for imparting training to railway operators.

In addition, the service engineer shall provide hands on training to railway staff in

calibration operation, repairing and maintenance of the machine in field to make them fully

conversant with the machine. The engineers shall also advise the Railways on appropriate

maintenance, testing, operating, repair and staff training facilities that are necessary for the

efficient performance of the machines.

24. WARRANTEE AND POST WARRANTY MAINTENANCE CONTRACT

The machine shall be warranted for 24 months from date of commissioning at ultimate

destination in India Design modification made in any part of the machine offered, the

warranty period of 24 months would commence from the date of modification and proving

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test of machine for the purpose of that part and those parts which may get damaged due to

defects in the new replaced part. The cost of such modification should be borne by the

supplier.

Other warrantee and post warranty clause wise term and conditions are attached as

Annexure –XI.

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Annexure I

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Annexure II

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Annexure III

Page 29 of 48

Annexure- IV

Scope of Training to be imparted by Manufacturer/Supplier to IR Personnel

The training program shall consist of the following modules-

1. For Senior Engineering officers of IR-

Four senior IR personnel shall be given training for a period of two weeks in

manufacturing plant of manufacturer/supplier and/or affiliated institute/training centers

and field operation where the machines are already in operation. Broad scope of this

training shall be to provide quality training in the areas of management of grinding,

machine familiarization, machine utilization, managerial aspects of operation and

maintenance of the machine, grinding strategy, best practices for optimal performance,

reporting, quality control, producing quality rail profiles, progressive review of grinding

strategy program, important safety aspects, vendor support.

2. For Track Machine organization Personnel –

This training will cover operation and maintenance of the machine. The broad scope of

this training will be as under:

Machine’s general arrangement including air systems, mechanical systems,

hydraulic systems, electrical systems, rail measurement systems, controls etc.

Operation of the machine in working mode (grinding) and travel mode.

Maintenance and overhauling of rail grinding machine.

Recording of rail profiles, use of Rail Inspection data and preparing the grinding

program.

Trouble shooting skills.

Responses of emergency situations

Basics of producing quality rail profiles.

The training will be conducted as per following sub-modules-

2.1. 12 IR personnel shall be given training for a period of Three weeks at contractors

manufacturing premises about machine assembly line in different shops, operation,

repair and maintenance. Also they will be given on-site training in field operation

abroad where same type of machine is already in operation for the contract.

2.2. In India, training of 12 IR personnel per machine for four weeks will be given in

operation and maintenance of the machine. Out of four weeks, at least two weeks

training will be imparted at the site of commissioning of the machines and has to be

completed before commissioning of machines. The remaining period of training will be

imparted in one or two modules spread over warranty period in the form of

refresher/updating training at the time of delivery of each machine. Details of the

proposed program should be given in the offer.

3. For P-Way Personnels –

Page 30 of 48

This training will cover design, planning, quality control, monitoring and review of

grinding program. The broad scope of this training will be as under:

Technical aspects of Rail Grinding and the benefits

Rail grinding functions and best practices for optimal performance.

Basics of producing quality rail and wheel profiles.

Rail and wheel interaction.

Technical aspects of rail lubrication, and planning the lubrication strategies.

Understanding and development of rail grinding program based on RCF,

surface defects and profile deterioration.

Monitoring of rail grinding result, its benefits and review of the grinding

program.

Rail Grinding Implementation and quality control.

Track inspection and data collection for rail grinding

Designing of optimal rail- wheel profiles

Establishment of test sites and monitoring

Designing rail grinding strategies and program

The training will be conducted as per following sub-modules-

3.1. 12 IR personnel shall be given three weeks training at manufacturer’s premises and/or

affiliated institute/training centre, this training shall include taking rail profile, wheel

profile, work on simulation software for different contact location of rail-wheel

interface, designing theory for developing required rail profiles, different pattern for

achieving the required rail profile and calculate rail life and such other aspects in the

contract.

3.2. In India training for 12 IR personnel per machine for six weeks will be given at site of

grinding / railway premises. This training includes taking rail profile pre-post grind

and use of other handheld gadgets for inspection of grounded rail and contact bend

before and after, how to maintain data base for grind quality, for establishing efficient

Rail Grinding Management system on Indian Railways for each machine. This module

of training may be staggered in suitable phases prior to supply of machines, post

supply and mid warranty review/refresher.

4. Tenderers are required to submit detailed proposal of the training program along with

their offer. The topics, detailed content of training, demonstrations, site visits and

hands-on experience should be elaborated in detail in the offer. The names of

manufacturing premises, affiliated institute/training centre where abroad training is

proposed to be conducted should be detailed in the training proposal in the offer.

Further details of places where field visits, demonstrations, hands on experience etc are

proposed to be conducted may be submitted within 90 days of signing the contract

agreement.

5. All the cost for arranging and facilitating the training are to be borne by the supplier.

Tenderers are required to quote the prices for training as per tender conditions.

However training as per 2.2 and 3.2 will be at suppliers cost and nothing extra shall be

paid for the same. The cost of boarding, lodging and air fare of IR personnel shall be

borne by the purchaser and should not be included in tenderer’s quote.

Page 31 of 48

Annexure- V

Page 32 of 48

Annexure-VI

INSPECTION CERTIFICATE

CERTIFICATE OF INSPECTION OF TRACK MACHINE( )

BY INSPECTING OFFICAL AND APPROVAL FOR DESPATCH OF MACHINES

(STRIKE OUT WHICHEVER NOT APPLICABLE)

This is to certify that I have inspected the machine-----------------------------------(type)

bearing SL No.----------------------------------------------------------------from (date) ----------

---------- to----------------------- (at place) ------------------------ for its conformity/non-

conformity with respect to the laid down Technical Specifications in contract Agreement

No.----------------- dated ------------------ between President of India through Director

Track(Machines) and M/s (Name of Supplier)----------------------------------------------------

----------------------------------------------------------------------.

The detailed inspection Note regarding its conformity/non-conformity to the laid

specifications is enclosed along with an Annexure’A’. It is observed that (strike out

whichever is not applicable):-

The machine conforms to all laid down specifications.

The machine conforms to all the laid down specifications except those at

Sl.No. ---------------

The above deviations are minor/major affecting/not affecting the performance

of the equipment in substantial way.

The following T and P/manuals/drawings are to be supplied along with the machine:

1.__________________________

2.__________________________

3.__________________________

Based on the above, the machine is certified/not certified to be conforming to the

specifications.

The machine is approved/not approved for dispatch to __________________

(consignee) Indian Railway.

SIGNATURE AND DATE

For M/s _____________ INSPECTION OFFICIAL

_____________________ (NAME AND DESIGNATION)

for and on behalf of President of India P

Page 33 of 48

ANNEXURE-VII

The speed potential of the machine offered by the firm should be established based

upon oscillation trials conducted in India. The tests will be conducted at speed usually 10%

higher than the maximum speed potential indicated by the firm for the machine under

consideration and the following criteria satisfy for the same. For conducting the tests, a

section of mainline track will be selected over which there is no temporary speed restrictions

and which is considered by the Railway as being in a generally run down condition for

mainline standards, but without speed restrictions. The vehicle will be tested generally for

new and worn clearance conditions and where relevant for operation in the forward and

backward directions. The vehicle selected for tests will be one in average condition for

normal maintenance.

The criteria applicable for establishing speed potential will be as follows:

i) A lateral force lasting more than 2 metres should not exceed the Prud

Homme’s limit of 0.85 (1+P/3) where P is the axle load.

ii) Isolated peak values exceeding the above limit are permissible provided the

record shows establishing characteristics of the vehicle subsequent to the

disturbance.

iii) A derailment coefficient should be worked out in the form of ratio between

the lateral force (hy) and the wheel load (Q) continuously over a period of

1/20th

second; the value HY/Q shall not exceed 1.

iv) The values of acceleration recorded in the cab at location as near as possible

to the bogie pivot (as near as possible to axle in case of four wheelers) shall

be limited to 0.55g both in vertical and lateral directions. The peak values

upto 0.6 g may be permitted if the records do not indicate a resonant tendency

in the region of peak value.

v) In the case of such vehicles where measurement of forces is not possible, the

evaluation shall be in terms of ride index based on the accelerations measured

as detailed in Para 2 (iv) above which shall not be greater than 4.5 but a limit

of 4.25 is preferred.

vi) A general indication of stable running characteristics of the vehicle as

evidenced by the movement of the bogie in straight and curved track and

lateral force and derailment coefficient of accelerations as the case may be.

Page 34 of 48

Annexure: VIIIA

Particulars Required in Respect of the Rolling Stock Under Consideration

1. A diagram showing elevation salient dimensions :

Wheel spacing, Wheel diameter, bogie centres,

and axle load.

a) i) Overall length of the vehicle :

ii) Length over head stock :

iii)Length over buffers :

iv) Distance apart for Centre of buffers :

v) Max./Min. height of centers of buffers

above rail level :

b) i) Wheel base :

ii) Axle load (max) :

iii) Bogie Centres :

2. Wheel dimension :

i) New :

ii) Worn out :

3. i) Tread and flange profile of the wheel :

indicating clearly whether it is Indian

Railway standard profile or differs from

standard flange profile.

ii) Wheel gauge dimension – :

(back to back of tyre flange).

4. Whether the stock is designed to be used as :

a general purpose or in a closed circuit in

specified sections under defined conditions.

5. Maximum design speed

i) Own Power :

ii) In train formation :

6. Unsprung weight per axle in tonnes

i) Driving axle :

ii) Running axle :

7. Expected lateral force in tonnes per axle :

at maximum design speed.

Page 35 of 48

8. Method of operation - :

Whether single only or coupling together is

possible. If coupling is possible, the number

which can be coupled and what is trailing load.

9. Maximum tractive effort at start and at the speed

of operation -

i) at working drive at start :

at operation speed :

ii) at transfer drive at start :

at maximum speed :

10. Maximum braking force coming on to the rails per wheel

a) at working axle :

b) at transfer axle :

11. Drawing indicating suspension arrangement details :

of bogie and axle.

12. Height of centre of gravity from rail level :

13. Height of floor from rail level :

14. Type of coupler provided -Indian Railways Standard

Coupling :

Buffer :

15. Any infringement to the moving dimensions :

Sketch provided in the Indian Railways Standard

Schedule of Dimensions – Chapter IV (A).

Page 36 of 48

Annexure: VIIIB

Following information as detailed below is also required along with the information

required as per Annexure ’A’ for processing the case for issue of provisional speed

certificate for new vehicle.

S.No Item

1. a) Brake System details

b) Gross Braking Ratio

2. Brake rigging arrangement drawing and calculation of braking force

3. Maximum Braking Effort. at start and at the speed of operation -

a) at working drive at start :

at operation speed :

b) at transfer drive at start :

at maximum speed :

4. Characteristics of springs used in suspension indicating free height, working height,

dynamic range, stiffness and locations etc.

5. Characteristics of the dampers if used, and over all damping factors and locations of

dampers.

Calculation of the following frequency of the vehicle to be attached :-

i) Bouncing ii) Pitching iii) Rolling

Wave length of free axle and bogie

6. Write up and salient design calculation on suspension system, type of suspension-

whether it is of coil suspension with or without dampers and laminated bearing

springs and double link suspension.

7. What are lateral clearance of axle box / horn, wheel flange/rail and other locations

for the negotiability of the vehicle on curve and turn out (enclose Vogels Diagram

for negotiability on maximum degree of curve and turn out permitted on Indian

Railways) of new and worn out wheel.

8. Wheel and axle assembly drawings

9. Calculation for flange force

10. Technical specifications of Vehicle supplied.

11. Calculation of natural frequency

12. Calculation of spring characteristics and critical speed of the vehicle.

13. Simulation result showing ride index, lateral force and acceleration results.

14. A certificate regarding the speed of the vehicle for which it has been designed.

Page 37 of 48

Annexure VIIIC

Machine details required for simulation of machine on NUCARS or similar Track-vehicle

simulation software

SL.

NO.

Component’s Name Parameters required

C.G. of component in x,

y, z direction from rail

level in mm (Referenced

point 1st axle)

Mass in Kg and Mass moment of inertias in Kg-

m^2 of

component in three dimension space about their

C.G

X Y Z Mass Ixx Iyy Izz

1. Super structure with

vehicle frame (machine

structure kept on

secondary suspension of

front and rear bogie)

2. Front Bogie frame

including brake rigging

3. Rear Bogie frame

including brake rigging

4. Transmission system

device (hydraulic.

Mechanical or electrical

traction motors)

5. Wheel axle set including

axle boxes which

constitute the unsprung

mass

6. Mass of Items included

in unsprung mass

partially or fully along

with their name per axle

1

2

3

4

5

6

Total

unsprung

mass in

tonnes

7. Total weight of Front bogie Rear bogie Machine Full weight of vehicle

Page 38 of 48

components in tonnes full assembly full assembly frame

full

structure

(front bogie + rear bogie

+vehicle car body or super

structure)

8. Suspension stiffness

details in Kg/mm

Primary suspension element stiffness

per axle box between bogie and axle

box

Secondary suspension element

stiffness

per side between bogie and machine

frame

Vertical stiff Lateral

stiff

Longitudi

nal stiff

Vertical

stiff

Lateral

stiff

Longitudinal

stiff

9. Damping force details

( If hydraulic damper

used give there rating

force per meter/second)

10. Clearance in mm or

radian provided for

motion between bogie

frame and machine frame

for relative motion

(motion stopper)

Vertical direction Lateral

direction

Longitudi

nal

direction

Rotation

about

vertical

axis

Rotation

about

lateral axis

Rotation about

longitudinal

axis

11. Dimension of location of

suspension elements

Detail of location of suspension springs

and dampers and shock absorbers with

support drawing

Detail of location of suspension springs

and dampers and shock absorbers with

support drawing

12. Details of centre pivot

arrangement working

and location

Provide detail arrangement drawing and description

13. Set of drawings and

design description

Concerning with general arrangement of vehicle, bogie general arrangement,

suspension arrangement details, suspension clearances drawing, detail written

description of configuration and loading pattern accompanies design particular

of vehicle bogie.

Page 39 of 48

Annexure-IX

200 mm

300 to 600 mm

INDIAN RAILWAYS 250 TO 600MM in bold & black color

Series NO.--- -------. 200 mm in black color

Manufacturer’s Name

Manufacturing Year -------.

200 mm

Page 40 of 48

Annexure-X

List of Track features

1. Km post,

2. TP/OHE Mast,

3. Pt.& Crossing In

4. Pt.& Crossing out

5. Level Crossing,

6. Switch Expansion Joint,

7. Fish plated joint

8. Axle counter

9. Bridge () In,

10. Bridge () Out,

11. Curve In,

12. Curve Out,

13. Tunnel In,

14. Tunnel Out,

15. 10 spare keys as user options.

16. Platform () In.

17. Platform () Out.

Page 41 of 48

Annexure-XI

1. OPERATION AND MAINTENANCE CONTRACT (DURING WARRANTY

PERIOD)

The following clauses outline the key requirements of the O&M conditions for Indian

Railways to be met by the supplier for a period of 24 months post commissioning:

1.1 The supplier or their designated Indian agent/Indian counterpart has to execute

works of Operation & maintenance of 72 stones Rail Grinding Machine which will

be deployed over many Zonal Railways as per the instructions of Consignee Zonal

Railways office. During the execution of the contract fuel, oil, water and lubricants

are to be provided by Zonal Railways free of cost to the supplier.

1.2 To operate & maintain complete the 72 stone Rail Grinding machine fully utilizing

it’s potential. The tenderer is responsible for ensuring the availability of machine for

08 hour every day for grinding operation (which might be increased by up to 2 to 3

hours depending on traffic condition over IR during operation). During maintenance

shift, the stipulated maintenance of RGM, stipulated preventive checks and schedule

maintenance of RGM machine including all assemblies (like engines, generators,

electrical control system etc.) or sub-assemblies (various water & HSD oil pumps

,sensors etc) as specified by OEM/supplier updated time to time to ensure it’s

upkeep shall be carried out.

1.3 The supplier or their designated Indian agent/Indian counterpart, has to provide

sufficient number of skilled/semi-skilled staff required (Minimum 12 staff including

6 Supervisors at a time) for operation and maintenance of RGM. Grinding operator

shall be certified by the OEM and with valid competency certificate in train

operation issued by ZRTI/IR and medically fit in A-1 Category. In case

initial/refresher course to be done for G & SR from ZRTI/IR during the currency of

this contract, the same shall be got done for the operators by the contractor and it

shall payable as applicable. Zonal Railways shall facilitate in expediting the process.

All the operators shall have valid PME certificate issued by IR and all the cost for

medical examination connected with PME, shall be payable by the contractor.

1.4 One 4 wheeler vehicle in good condition with proper road permit and

insurance(Safari/ Scorpio or similar) for transporting men and material required for

day to day working will be provided by tenderer during O&M period for use by O

& M crew and IR crew (on RGM) without any extra payment.

1.5 The RGM will work on IR track with the trains running on adjacent tracks. The

contractor must ensure the care /safety/health hazards of the labours engaged by

him/her during the course of the execution of work. Necessary safety equipment

shall be provided by the contractor for the staff engaged by the tenderer and also for

2-4 IR official nominated on this machine. No extra amount is payable toward this.

1.6 Railway shall provide adequate and appropriate security at their disposal to protect

and preserve the RGM Machine from anti-social elements especially in insurgency

defined areas, where the machine maybe required to operate from time to time.

1.7 The contractor's staff & labour shall not have any claims of appointment in

Railways in future.

1.8 Authorized Railway's representative having route learning of the particular section

where the RGM is working will be present for supervising the grinding work and to

Page 42 of 48

monitor the movement of the RGM from one section to another. RGM shall not be

moved without authorized Railway's representative. The same would be provided

free of charge.

1.9 All tools and plants, drawings, manuals which are supplied by the manufacturer to

the Railways will be handed over to the contractor free of cost for use along with

the machine. All these to be handed over back in good condition after expiry of the

contract period to authorized Railways.

1.10 RGM shall be made available for grinding operation for minimum period of 25 days

in a month and 75 days in consecutive 3 months. The balance 15 days are meant for

maintenance functions during which time all maintenance activities are to be

completed by the tenderer. While the RGM is on transit from one station to another

or waiting for loco for hauling, it will be considered as availability unless the RGM

is under breakdown preceding to this.

1.11 The supplier will be responsible for ensuring the availability of machine for eight

hours every day for at least 25 days a month and the availability certificate will be

rendered (as per enclosed Annexure - A). During these 8 hours (which may be in

two shifts with one break of maximum up to 3 hours) of daily availability of

machine, the working hours (actual grinding) will be in general for about 4 hours

per day.

The machine availability for penalties purposes will be worked out by taking

average availability of machine after 6 months (150 days over 6 months).

Availability of machine for work less than 150 days in half year on account of

supplier during the warranty period will invite a penalty of Rs 30,000/- per day and

the penalty certificate will be rendered (as per enclosed Annexure - B)

1.12 When the RGM is on transit with its own power from one station to another, and

RGM shall be made available for movement in two shifts of 10 hours each (2x10

hours) in 24 hours time frame till it reaches destination, since there will be no

routine maintenance. The staff of operation and maintenance shall be so

redistributed that at least one operator and three other staff are available in each

shift during transit.

1.13 All the fixtures in Camping coach shall be maintained in good condition. Special

cleaning of camping coach (once a month or earlier) to be carried out so as to

maintain in excellent condition. All electrical, plumbing, furniture, electronics,

computers/laptop, TV&DVD, Genset, Washing machine, freezer, geysers,

microwave/oven, communication and all other fixtures available in camping coach

to be maintained in good fettle at all times and at the end of the contract period. The

fixtures would be handed over the Zonal Railways in good condition, as received at

the beginning of the contract.

1.14 Special cleaning of RGM to be carried out once a month (as far as possible) with

detergents and other cleaning agents to remove all soot, dust etc. and to keep the

entire machine in good appearance. RGM will be stabled at a place so that adequate

water (to be provided by Zonal Railways) & non-OHE siding are available so as to

ensure proper cleaning. Patch panting at rusted locations should be done after

cleaning with matching colour. No amount is separately payable towards this.

1.15 Complete and up to date records for daily, weekly and monthly maintenance will be

maintained by the contractor and countersigned by IR officials. The

daily/weekly/monthly and all progress report, grind history in the prescribed format

Page 43 of 48

shall be mailed to nominated officials of division/zone/RDSO/Rly board. For which

required arrangement shall be made on the machine by the contractor.

1.16 The contractor shall maintain history book, Log book and all othe documents

prescribed for track machines on IR.

1.17 Contractor shall furnish adequate VHF sets for crew communication for safe

operation of RGM. This should include at least 6 hands free devices.

1.18 As prescribed in Clause 1.26 (Annexure-XI), contractor shall submit total cost of

the spares likely to be consumed during the warranty period. Total quantity of

spares supplied by the contractor for operations and maintenance under warranty

period shall be kept in Railway stores of Zonal Railways and shall be issued to

RGM as per the machine requirement.

1.19 Each party agrees to indemnify, defend, and hold harmless the other party from all

liability, cost or expense (including any court costs) caused by the joint and/or

concurring negligence of the parties, arising on account of injury to or death of any

employee, agent or representative of the indemnifying party during the performance

of the Services or who shall, if not performing Services, be present as a bystander or

otherwise on the property of either party, provided always, however, that if the

injury or death to an employee of an indemnifying party is caused solely by the

negligence of the other party then this indemnity and hold harmless provision shall

be null and void, and the party who solely caused the injury or death shall bear the

cost or expense. Notwithstanding any provision herein to the contrary, Tenderer’s

total cumulative liability for any or all claims arising out of this agreement shall not

exceed the three month value of this O&M portion of the contract.

1.20 If there is deficiency of staff on RGM w.r.t. minimum stipulated staff in operation

and maintenance (minimum staff. in O & M shift put together), penalty of Rs

3000.00 per head per shift or part thereof shall be imposed. For maintaining

attendance of the staff for this purpose, the contractor has to provide biometric

attendance system in the camping coach & shall ensure it is working condition

always. No extra payment shall be admissible on this account.

1.21 The maintenance role encompasses undertaking all schedule/periodic/ routine of

RGM machine including all assemblies (like engines, generators, electrical control

system etc.) or sub-assemblies (various water & HSD oil pumps, sensors etc) as

specified by Supplier / OEM as well as RDSO updated from time to time, either by

day or night. OEM recommended spares will be transported from Railway stores to

the machine and the released spares/material from machine to Railway stores, by

Zonal Railways.

1.22 Scheduled Maintenance:

i. Daily maintenance will be strictly followed after grinding operations. Other

schedule maintenance (weekly, monthly, two monthly, quarterly, half yearly,

yearly and two yearly checks) are to be performed at appropriate time

intervals in the balance time available after offering the RGM for operational

activities.

ii. Routine maintenance of undercarriage systems shall be undertaken by the

tenderer.

iii. Tenderer shall be responsible towards mounting and dismounting of

unserviceable/ Serviceable/New components/ parts / materials on the RGM.

Zonal railways shall be responsible for providing serviceable components /

parts/ materials on the machine for fitment and suitability tests.

Page 44 of 48

iv. Wheel and Bogie turnings (if needed) will be coordinated and executed by

Zonal Railway. Wheel turning charges as applicable by w/shop per wheel

would be paid by the tenderer.

v. Workshop facility if needed shall be provided by Zonal Railways.

1.23 Maintenance of Records

i. Maintenance records during Schedule and breakdown maintenance shall be

maintained in hard copy as well as soft copy as per format provided and

updated from time to time.

ii. These records shall be provided to Zonal Railway by the crew on the machine

in a timely manner.

iii. Tenderer shall maintain a standard daily report accurately depicting

operational times, delays, and machine availability. Zonal Railway crew/

representative has to sign daily report based on satisfactory completion of

daily operational services. The signed daily report shall be the basis for

invoicing and shall constitute Zonal Railway’s acceptance of day to day work

apart from the completion of scheduled maintenance in timely manner.

1.24 Test Site Management:

(i) As part of the O&M Services provided by the tenderer or their designated Indian

agent, 12 test sites would be actively managed by them. This would include atleast 4

mild curves, 4 sharp curves and 4 tangents. Breakup would be as follows:

- 2 mild curves at same location on UP Line and DOWN Line = 4 Total

- 2 sharp curves at same location on UP Line and DOWN Line = 4 Total

- 2 tangents at same location on UP Line and DOWN Line = 4 Total

Final = 12 test sites and would be jointly selected by IR/Zonal Railways and the

tenderer / contractor.

These locations should be maintained as permanent test sites and should be re-marked

periodically by proper paint by Zonal Railways. Format for Test site location

marking by paint as ben shown as Annexure C.

(ii) As part of requirement of the Test site management, tenderer or their designated

Indian agent shall record the following for each test site:

- Pre Grinding Rail profile with the help of MiniProf, surface photograph and dye

penetration test, within 10 days before grinding

- Post Grinding Rail profile with the help of MiniProf, surface photograph and dye

penetration test, within 10 days after grinding

- Maintaining proper record of the same.

- Sharing run over run analysis for all 12 test site locations duly countersigned by

designated IR official.

- Review of grinding pattern changes needed, if any post analysis

- Review for further changes in profile and grinding cycle.

(iii)As part of this exercise, any existing templates would also be reviewed and modified

as needed.

1.25 During the currency of the O&M period, the supplier or its Indian agent may seek

documents for importing spare parts/material/testers/manuals/equipment’s on

requirement basis for Customs clearance. These will be provided by Consignee

Zonal Railways in required format for speedy clearance on arrival at port.

Page 45 of 48

1.26 Spare Parts:

Complete and exhaustive list of OEM spare parts along with their unit cost, list broken down

to the last level for Rail Grinding Machine, classified into following categories shall be

furnished by the tenderer:-

i. Recommended – Spare parts covered under warranty period and will be either

replaced/repaired. During repaired/replacement period, Recommended parts held on

Railway Inventory can be fitted on the machine on returnable basis and is provided

by IR only to ensure machine uptime.

ii. Consumables – As per actual consumption, during the warranty period is to be

provided by the contractor.

It may be noted that the Spare Parts List along with unit cost of each part indicated for O&M

Period must indicate the anticipated quantity of use. This would be used to establish a

budget and the total budget per machine, as furnished by the tenderer, would remain fixed,

while actual used quantities may vary based on usage. During the 24 month O&M period, in

case spares beyond the budget, need to be used, the additional spares would be supplied free

of cost by the supplier. Cost of Spares needed for the 24 month O&M period would be

considered as part of price calculation for the determination of successful bidder.

It is important to note that spares not included in the list would be provided by the supplier

free of charge during the O&M period. The supplier must ensure that spares are properly

budgeted keeping in mind the IR working and environmental conditions.

Initial batch of spares , costing up to 30% of the total budget for spares would be supplied

with the machine. Remaining 70% of the spares can be supplied in instalments, as per the

experience gained in the field/ actual requirement. All such spares shall be kept in the

custody of consignee railway. The railway shall issue such spares to the machine as per

O&M requirement.

Tenderer should insure availability of spares for machine stipulated service life of 15 years

by providing ware house or store in India for uninterrupted working of machine.

Furthermore, spares per year per machine should generally not exceed 5% of machine price.

2. POST-WARRANTY OPERATION & MAINTENANCE CONTRACT:

2.1 The supplier shall quote for a two year extension of O&M services after the expiry of the

warranty period. The additional extension for 2 years is on the sole discretion of

Railway Board / Zonal Railways.

2.2 All terms and condition for post warranty O&M of RGM shall be same as in case O &

M of RGM under warranty, except clause for spare parts.(1.18, 1.26)

2.3 Spare Parts:

2.3.1 Spares for repair/maintenance and consumables would be supplied by Railways. Rate

contract, for supply of spares will be fixed by respective Zonal Railways separately.

Page 46 of 48

ANNEXURE A

QUARTERLY AVAILABILITY CERTIFICATE FORMAT

“THE OPERATION AND MAINTENANCE OF RAIL GRIDING MACHINE HAS

SATISFACTORILY PERFORMED FOR DAYS DURING THE THREE

CONSECUTIVE MONTHS / 90 DAYS PERIOD FROM TO FOR

WHICH PAYMENT INSTALMENT IS CLAIMED”.

The details of Rail Grinding Machine availability days for Quarter is furnished below.

Quarter Month M/C Availability Days M/C Non-Availability Days

Total days

Average no of days available/month = Days

Dy CE/TM/Lines

C/- CE/TM For kind information.

C/- Supplier,

Page 47 of 48

ANNEXURE B

HALF YEARLY PENALTY DEDUCTION CERTIFICATE FORMAT

“AMOUNT OF PENALTY DEDUCTION TO BE MADE AS PER CLAUSE NO 1.11 OF THE

TECHNICAL SPECIFICATION TO RAILWAY BOARD CONTRACT AGREEMENT NO

IS ”.

Dy CE/TM/Lines

C/- CE/TM For kind information.

C/- Supplier,

Page 48 of 48

ANNEXURE C

Documents

Annexure-I Specification of Rail Grinding Machine · 2019-12-03 · Page 1 of 48 Annexure-I Specification of Rail Grinding Machine 1. General 1.1. These specifications provide the